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FREE FORM FIBERS L.L.C.

Address

10 CADY HILL BLVD
SARATOGA SPRINGS, NY, 12866-9045
USA

View website

UEI: HTJ8WJJPK8T8

Number of Employees: 12

HUBZone Owned: No

Woman Owned: No

Socially and Economically Disadvantaged: No

SBIR/STTR Involvement

Year of first award: 2010

Phase I Awards

Phase II Awards

75%

Conversion Rate

$2,072,989

Phase I Dollars

$9,047,959

Phase II Dollars

$11,120,948

Total Awarded

Awards

Up to 10 of the most recent awards are being displayed. To view all of this company's awards, visit the Award Data search page.

Hybrid SiC-SiC CMCs

Amount: $1,100,000 Topic: C56-40v

This DOE SBIR Phase II proposal builds upon two major manufacturing technology breakthroughs to answer DOEĺs call for: (1) New innovative accident tolerant LWR fuel cladding/assembly concepts that have the potential to support achieving very-high fuel burnups and (2) Improved fabrication techniques or characterization techniques for silicon carbide accident tolerant LWR fuel cladding and fuel structures to improve the overall fuel performance. Free Form Fibers comes at the table with manufacturing-ready solutions that can now address the next challenge: Testing of the products enabled by these manufacturing advances. In this instance, we propose to put to the test, with the support of a major Prime partner, a technology it calls ôthe ultimate solution for Light Water Reactor (LWR) Accident Tolerant Fuel (ATF).ö In this instance, we are proposing a hybrid metal-silicon carbide composite, whereby the silicon carbide composite is fabricated over a zirconium cladding at a temperature low enough to prevent phase change in the zirconium, and yet ensure bonding between the ceramic matrix composite and the metal base. Looking beyond the technical challenge, the silicon carbide fiber products created by Free Form Fibers and demonstrated in silicon carbide composites are far more economical and their processing far simpler than alternate ceramic matrix composite production processes. This means a commercialization path is now opening that not only serves nuclear but has the potential to sustain a much larger market base.

SBIR

Phase II

2024

DOE

HIGH TEMPERATURE, LOW DIELECTRIC CONSTANT CERAMIC FIBERS FOR MISSILE APPLICATIONS

Amount: $1,199,998 Topic: N211-059

The technology that has sustained tactical missile radomes and other electromagnetic windows is being outpaced by the increasingly challenging thermal, environmental and structural demands of hypersonic flights. New engineered materials, that exceed state-of-the-art capabilities are required to support the next generation of hypersonic vehicles. Silicon nitride is the next-generation material candidate. However, silicon nitride is a ceramic material. As such, it is a strong yet brittle material that can fail catastrophically. The prevention of catastrophic failure necessarily relies on Ceramic Matrix Composite (CMC) technology, an engineered material consisting of fiber reinforcements embedded within a ceramic matrix, in this instance, silicon nitride fibers. This proposal addresses a void in the market: There are no commercially available silicon nitride fibers, and for good reasons. How does one make fibers with a material that does not melt, does not soften, and does not tolerate the presence of impurities at high temperatures? Free Form Fibers does it with lasers. Our proprietary fiber laser printing technology has been used to produce like materials, such a silicon carbide. Under the proposed project, Free Form Fibers will seek to adapt its fiber laser printing technology to the fabrication of fabrication of silicon nitride fibers. Once this goal is reached, Free Form Fibers will move toward establishing a domestic fiber production capacity. In parallel, Free Form Fibers will seek to establish a prototype production demonstration for silicon nitride CMC components.

SBIR

Phase II

2023

DOD

NAVY

Hybrid SiC-SiC CMCs

Amount: $200,000 Topic: C56-40v

This DOE SBIR Phase I proposal builds upon two major manufacturing technology breakthroughs to answer DOE’s call for: (1) New innovative accident tolerant LWR fuel cladding/assembly concepts that have the potential to support achieving very-high fuel burnups and (2) Improved fabrication techniques or characterization techniques for silicon carbide accident tolerant LWR fuel cladding and fuel structures to improve the overall fuel performance. Free Form Fibers comes at the table with manufacturing-ready solutions that can now address the next challenge: Testing of the products enabled by these manufacturing advances. In this instance, we propose to put to the test, with the support of a major Prime partner, a technology it calls “the ultimate solution for Light Water Reactor (LWR) Accident Tolerant Fuel (ATF).” In this instance, we are proposing a hybrid metal-silicon carbide composite, whereby the silicon carbide composite is fabricated over a zirconium cladding at a temperature low enough to prevent phase change in the zirconium, and yet ensure bonding between the ceramic matrix composite and the metal base. Looking beyond the technical challenge, the silicon carbide fiber products created by Free Form Fibers and demonstrated in silicon carbide composites are far more economical and their processing far simpler than alternate ceramic matrix composite production processes. This means a commercialization path is now opening that not only serves nuclear but has the potential to sustain a much larger market base.

SBIR

Phase I

2023

DOE

Multifunctional Structures for Extreme Environments made by Laser CVD

Amount: $1,248,165 Topic: AF224-D022

The Department of the Air Force is requesting support for long-term needs with regards to shape-stability in extreme environments via a high-pressure chemical vapor deposition process that enables both fine features for transpiration, but also enables eas

SBIR

Phase II

2023

DOD

USAF

Shaped, High-Strength Silicon Carbide Fibers for CMCs in Hypersonic Applications made by LCVD

Amount: $899,801 Topic: N231-D04

The mission of the work presented in this proposal is to develop a novel, stable, domestic process for manufacturing shaped, silicon carbide fibers in a timely and cost effective manner for advanced ceramic matrix composites (CMCs) intended for use in hypersonic applications. The goal is to understand how the processing parameters affect the fiber properties and to develop the process controls needed to govern the fiber properties. Free Form Fibers (FFF) proposes to demonstrate laser-induced chemical vapor deposition (LCVD) as this novel process. LCVD is a material-agnostic, additive manufacturing process capable of producing high-purity material in fiber form, and is easily adaptable to large-scale manufacturing. The process offers high-fidelity control over processing parameters that can control material compositions and fiber geometry including varying diameters. For this proposal, short silicon carbide fibers of varying compositions and shape will be produced, characterized, and down- selected for large-scale production based on their high-temperature and high-strength performance. Large-scale production will be performed on a tool built for this purpose under this award. These fibers will be converted into a non-woven architecture and then processed into SiC/SiC CMCs coupons for mechanical testing and high-temperature conditions simulating hypersonic applications.

SBIR

Phase II

2023

DOD

NAVY

Fiber-embedded wireless sensors

Amount: $200,000 Topic: C56-40w

With this DOE SBIR Phase I proposal, Free Form Fibers is aiming to demonstrate a bio-inspired methodology to insert self-contained, self-powered sensors within multifunctional structural fiber reinforcements. This approach is especially suited for sensors [and actuators] for harsh environments, such as nuclear reactors. The envisioned technology of fiber-embedded systems, as well as its business model, are inspired by the phenomenal success of Micro-Electro-Mechanical-Systems (MEMS), which are now present in every smartphone, vehicle, and most consumer electronics. Contrary to MEMS, however, the proposed fiber-embedded systems are not add-on, but rather an integral part of composite materials. They are envisioned as seamlessly integrated, non-invasive, wireless, and an alternative to add-on fiber-optics sensors. The necessary manufacturing technology is protected under US and International patents. It is a form of Containerless, Material-Agnostic, Additive Manufacturing, specialized for filamentary structures and is referred to 1½-D Printing. The proposed approach is quite generic. If demonstrated for one type of sensor – say heat flux – the same approach can be used for other sensing devices (e.g., neutron flux). The approach also has a great potential for integrated structural health monitoring in both nuclear and non-nuclear applications. By analogy to MEMS, the expectation is that mass manufacturing can bring down the per device cost so low that a large number can be integrated into a composite structure, forming the technological equivalent of a “nervous system.” Sensor interrogation is expected via microwave radio frequency, and lead to interpretation using Digital Twins, or Machine Learning and Artificial Intelligence. Ultimately, such a strategy could displace stationary non-destructive evaluation with on-board structural health monitoring.

SBIR

Phase I

2023

DOE

Design, Modeling, and Experimental Validation for life-optimization of Hydrogen Turbine CMC Components

Amount: $250,000 Topic: C54-21e

In preparation for the widespread implementation of ceramic matrix composites (CMCs) for hot gas path applications within hydrogen turbines, the Department of Energy, Office of Fossil Energy and Carbon Management seeks to encourage the development of process intelligence for CMCs operating at surface temperatures in excess of 1500ºC, for extended periods of time in hydrogen-rich environments. CMCs represent a new class of engineered materials for extreme environments that hold the promise of significant increases in energy efficiency and greenhouse gas reductions. Not only are CMCs a new class of composite materials, but their application in hydrogen turbines is sure to raise new technical challenges that have, so far, not been of concern to other domains where CMCs are considered. To address anticipated shortcomings with hydrogen powered gas turbines, research is needed to design, model and test alternative interphase coatings and Environmental Barrier Coatings for the intended conditions. To this end, Free Form Fibers (FFF) intends to team up with Materials Research and Design (MR&D) to implement a combined CIME-experimental approach leading to a CMC engineered for hydrogen turbines. FFF has unique capabilities to produce micro-composite samples with custom-made interphase coatings while MR&D has a proven history of modeling material behavior. The combined effort is expected to advance the state of the art for CMCs and build a predictive modeling capability to elicit the long-term behavior of such structures.

SBIR

Phase I

2022

DOE

High Temperature, Low Dielectric Constant Ceramic Fibers for Missile Applications

Amount: $246,500 Topic: N211-059

SBIR

Phase I

2021

DOD

NAVY

39s: Homogeneous Joining of Silicon Carbide fiber reinforced Silicon Carbide Matrix Composites

Amount: $206,500 Topic: 39s

In light of the Fukushima Daiichi nuclear disaster, the nuclear industry and policy makers are seeking novel, reliable approaches to safeguard against similar, future catastrophes. One path of interest is the development of accident tolerant fuel cladding tubes. These are designed to shield the environment from the eﬀects of nuclear fuel during normal operating conditions, as well as during worst-case scenarios, to mitigate the eﬀects of meltdowns. To achieve this goal, silicon carbide is being investigated as a new cladding material; however, hermetically joining silicon carbide tubes to end plugs presents a technical challenge. The work proposed here addresses this challenge by applying a new approach—embedded wire chemical vapor deposition—that can economically form a hermetic, homogenous seal between the joined parts. Mechanical characterization of this homogeneous joint will be the main objective of this investigation. Support for the proposed work has been expressed from industry. If successful, Phase II or Phase III follow-up funding would support the work needed to allow the proposed innovation to advance the realization of accident tolerant fuel claddings. Thus, benefiting the wider public by mitigating the eﬀects of a beyond-design-basis event.

SBIR

Phase I

2021

DOE

Ultra-Thin, 3-D Ceramic Matrix Composite Cladding

Amount: $1,100,000 Topic: 33b

The deployment of ceramic matrix composites (CMCs) to nuclear-related applications became acceler- ated after the 2011 Fukushima accident. In the US, this effort is administered by the Department of Energy (DOE) Office of Nuclear Energy (NE) under a Congressionally-mandated Accident-Tolerant Fuel (ATF) program. This effort still requires several technical advancements to achieve widespread use in nuclear reactor structures and fuel cladding. Silicon carbide (SiC), as part of a SiC matrix-SiC fiber system, is recognized as the primary material option to achieve the ATF goals, but present-day manufacturing presents multiple performance issues for nuclear fuel com- ponent manufacturers. These performance shortcomings include strength and thermal conductivity degradations due to manufacturing-induced damage and the environmental response of the material in nuclear environment. Free Form Fibers (FFF) proposes a novel approach to fabricate a non-woven fiber architecture for Ceramic Matrix Composites (CMCs) using its additive manufacturing-based Rapid Laser-Induced Chemical Vapor Deposition (R- LCVD) technology, which would eliminate the need for fiber weaving and also open an opportunity to create innova- tive metal matrix composite-ceramic matrix composite (MMC-CMC) hybrid structures. This non-woven design, termed micro trellises, would allow for several important technical advances needed to achieve the DOE and nuclear industry's goal for safe, high efficiency fuel designs. The non-woven architecture significantly reduces the residual porosity and increases the possible fiber volume fraction loading, while also curtailing manufacturing induced defects. These features minimize the necessary CMC component thickness, providing positive benefits to the bulk thermal conductivity, component weight reduction, and easier and quicker matrix formation via vapor infiltration. The program presented by FFF in this proposal aims to demonstrate the viability of fabricating metal-CMC hybrid cladding on the basis of micro trellis design. FFF has extensive capabilities to form SiC fiber arrays, trellis-like posts on substrates as well as coat fibers and posts with interface coating materials. FFF also introduces a novel approach to vapor infiltration of the matrix designed to minimize damage the underlying substrate to create a CMC component, or a MMC-CMC component. Component-level properties like thermal conductivity will be evaluated as well as more fundamental hydrothermal corrosion in nuclear reactor and mechanical properties of the trellis structures. The development of FFF's micro trellis will enable several needed technical advances for CMC technology, impact- ing a wide range of applications including the nuclear power, aviation, aerospace and gas turbines. One of the most significant improvements will be the reduction in overall CMC manufacturing economic costs for nuclear fuel reactor components such as cladding.

SBIR

Phase II

2020

DOE